Method of forming and mounting a handle



June 26, 1962 E. P. SUNl DHOLM 3,040,428

METHOD OF FORMING AND MOUNTING A HANDLE Filed May 29, 1959 /N 1 5 N TOR $49M Jain, M

A TTOR/VEYS.

Uited States Patent This invention relates to a method of forming and mounting a handle. More particularly, the method relates to a method for providing a transverse handle or handgrip on the projecting end of a rod, for example,

where it is desired to provide for the manual actuation of the rod. The method of this invention has particular utility in connection with the manufacture of handles for grease gun operating rods, such as the one illustrated in my prior Patent 2,43 6,701, issued February 24, 1948.

In the manufacture of grease guns it is necessary to 3,040,428 Patented June 26, 1962 ice open-ended tube, as indicated in FIG. 3 by the number 13. It will be noted that the opposite edges 12a and 12b of the sheet, as indicated in FIG. 2, have been brought together to'provide a longitudinal joint 14 in the tube of FIG. 3. Along joint 14 the edges of the sheet are in abutting relationship but are unconnected to each other.

It will also be noted that tube 13 as shown in FIG. 3 provides a circular opening 15 which is located intermediate the end thereof and is intersected by the joint 14. This opening can be formed in any suitable manner, such as by drilling after the tube 13 has been formed. However, it is preferred to follow the procedure illustrated in FIG. 2 wherein the edges 12a and 121) are provided with complementary semi-circular indentations or recesses before the sheet is rolled to the tubular shape of FIG. 3. When this is done, the opening i15 is automatically formed when the edges 12a and 12b are brought attach a handle or handgrip to the projecting end of the operating rod. In the usual design of grease guns, the operating rod extends through the rear cap into the barrel of the gun, and means is provided for releasably interconnecting the inner end of the rod with a plunger assembly within the barrel. In theoperation of such grease guns, it may be desirable to retract, advance, or rotate the plunger assembly by manually manipulating the projecting end portion of the operating rod,-and this may involve the application of considerable force to the rod, 1

such as when a heavy spring must be compressed in withdrawing the plunger.

The primary object of the present invention is to proprojecting end of a rod which is adapted for use in the manufacture of grease guns, and which provides the advantage of substantially reduced manufacturing costs as compared with prior methods while at the same time providing a rugged and durable handle. Further objects 3 being compressed between forming dies in one of the manufacturing steps;

FIG. 5, a side sectional view showing the tube of FIG. 3 applied to the end of an actuating rod as it would appear during another of the manufacturing steps;-

FIG. 6, a view similar to FIG. 5 illustrating a further manufacturing step and also the way in which the handle is interconnected to the rod in the final product; and

FIG. 7, a View identical to FIG. 5 except the end of the handle has a modified shape.

As already indicated, this invention is concerned with the method of forming and mounting a handle on the end of a rod, the external appearance of the final product being shown in FIG. 1 where the rod is designated by the number 10 and the transverse handle by the number 11. The procedure for making this handle will now be described in detail. 7 I

In accordance withthe present invention, the starting material for forming the handles is metal sheet stock.

I The method is applicable to any malleable metals, such as low carbon steels, aluminum, etc.

In FIG. 2 there is shown a rectilinear piece of metal sheet stock which has been cut to the size for forming a single handle, the flat sheet being designated by the number 12. The sheet 12 is rolled into the shape of an 30. vide a method of forming and mounting a handle on the p I into abutting relationship. I

Before the tube 13 is attached to the rod 10 to form the handle 11, it is preferred to go through the operation illustrated in FIG. 4. In this step, the extreme end portions of the tube 13 are turned inwardly under pressure to form an inwardly directed flange on each end thereof. One simple procedure for accomplishing these results is that illustrated in FIG. 4 wherein the tube 13 is compressed longitudinally between concave forming dies 16 and 17. FIG. 4 illustrates the appearance of the tube after the completion of the die forming operation wherein the extreme end portions of the tube are turned inwardly. Due to the pressure applied in this forming operation there is a cold flow of metal adjacent the outer ends of the joint 14 which results in overlapping of metal at the end portions of the unconnected edges along the inwardly directed flanges.

Following the step illustrated in FIG. 4, or directly following the step illustrated in FIG. 3 if desired, the metal rod to which the handle is to be attached, such as rod 10, is extended through the opening 15 into contact with a portion of the inner wall of the tube opposite the opening, as illustrated in FIG. 5. The rod 10 should be formed of a metal which is fusible with the metal of the tube 13. Also, it is desirable to have the rod of only very slightly smaller diameter than the minimum diameter of the opening 15 so that the rod will be snugly received within the opening. According to the method of this invention, it is not necessary to have the end of rod 10 rounded to conform to the internal curvature of tube 13. Good results are obtained even though the end of the rod is squared off, and is thereby prevented from forming a' full surface to surface contact with the inner wall of tube :13. One satisfactory relationship of these parts before fusing is shown in FIG.

In the next step of" the method, the end of the rod 10 is fused to the inner wall portion of the tube 13 to form a secure bond therebetween. These members are preferably united by heating the end of the rod and the wall portion to a fusing temperature while applying pressureto force the rod and wall portion into engagement. Such an" operation is illustrated diagrammatically in FIG. 6. An electrode 18 having a concave face is applied to theoutside of tube 13 over the wall portion of the tube which is to be fused to the end of rod 10. While heat is being applied by means of the electrode, pressure is applied to rod 10, as indicated by the arrow in FIG. 6, to force the rod into engagement with the wall of the tube. The appearance of the parts after the completion of this pressure fusion operation is shown in FIG. 6.

Following the completion of the steps just described, the handle is ready for use. As previously indicated, FIG. 1 illustrates the external appearance of the final product, the handle 11 being provided by the tube 13 which has been formed by the procedure previously described and united to the end of rod 10.

FIGURE 7 illustrates a modification of the attachment method which can be used if desired. As there shown, the rod 10' is scarfed or ground at 10a and 10B to provide the end with a taper which is is to be attached to tube 13', thereby permitting a larger surface to initially engage the inside of tube 13'. This will facilitate the welding operation and avoid burning of the rod.

While the method of this invention has been described in relation to a preferred embodiment thereof for purposes of illustration, it will be apparent to those skilled in the art that the method is susceptible to other embodiments than the one set forth herein and that certain of the details hereinbefore set forth can be omitted or varied without departing from the basic principles of the invention.

I claim:

1. In a method of forming and mounting a handle, the steps comprising providing a flat rectangular sheet of malleable metal with corresponding opposed semicircular recesses in the longitudinal edges of said sheet, rolling said flat sheet into the shape of an open-ended tube with longitudinal, unconnected, abutting edges, said opposed recesses and said longitudinal edges defining a circular opening intermediate the ends of said tube, turning the extreme end portions of said tube inwardly under pressure to form an inwardly directed flange on each end thereof, said pressure causing cold flow and overlapping of metal at the end portions of said unconnected edges, extending the end portion of a metal rod through said circular opening to bring the end of said rod into contact with a portion of the inner wall of said tube opposite said opening, and fusing the end of said rod to said inner wall portion to form a secure bond therebetween.

2. In a method of forming and mounting a handle, the steps comprising providing a fiat rectangular sheet of malleable metal with corresponding opposed semicircular recesses in the longitudinal edges of said sheet, rolling said fiat sheet into the shape of an open-ended tube with longitudinal, unconnected, abutting edges, said opposed recesses and said longitudinal 'edges defining a circular opening intermediate the ends of said tube, turning the extreme end portions of said tube inwardly under pressure to form an inwardly directed flange on each end thereof, said pressure causing cold flow and overlapping of metal at the end portions of said unconnected edges, extending the end portion of a metal rod through said circular opening to bring the end of said rod into contact with a portion of the inner wall of said tube opposite said opening, said rod having approximately the same diameter as said opening so as to be snugly received therein, and uniting the said end of said rod to said tube wall portion by applying heat and pressure thereto.

References Cited in the file of this patent UNITED STATES PATENTS 1,405,04a Kraft Jan. 31, 1922 2,109,470 Dake Mar. 1, 1938 2,120,150 Marshall June 7, 1938 2,126,473 Keller Aug. 9, 1938 2,162,088 Jonas June 13, 1939 2,179,089 Hauf Nov. 7, 1939 2,883,738 Morrow Apr. 28, 1959 FOREIGN PATENTS 11,696 Great Britain 1904 

